Manufacturing Process Assignment

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Saad Ur Rehmaan BME-B3-65

Danish Jalil BME

_–

B3-20

Azhar Hussain BME-B3-`56

Submitted To

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Assignment on Manufacturing process

Introduction

Manufacturin

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Process

Manufacturing

Manufacturing is the produis the production of goods ction of goods for use or for use or sale using labor sale using labor andand machines, machines, tools, tools, chemical and biological processing, or formulation. The term may refer to a range of human chemical and biological processing, or formulation. The term may refer to a range of human activity, from

activity, from handicraft handicraft toto high tech, high tech, but is most commonly applied to but is most commonly applied to industrial industrial production, production, inin which

which raw materials raw materials are transformed intoare transformed into finished goods finished goods on a large scale. Such finished goodson a large scale. Such finished goods may be used for manufacturing other, more complex products, such as

may be used for manufacturing other, more complex products, such asaircraft,aircraft, household

household or or automobiles, automobiles, or sold to or sold to wholesalers, wholesalers, who in turn sell them to who in turn sell them to retailers, retailers, who then sell who then sell them to end users

them to end users – – the " the "consumers”. Manufacturingconsumers”. Manufacturing takes turns under all types of takes turns under all types of economic economic systems.

systems. In a free market economy In a free market economy

Aluminium Piston Introduction

Primary manufacturing activity of Cast & Alloys was manufacturing aluminum pistons. The Primary manufacturing activity of Cast & Alloys was manufacturing aluminum pistons. The company has the capability to manufacture pistons in the diameter range 40mm to 200mm company has the capability to manufacture pistons in the diameter range 40mm to 200mm irrespective of complexity, adhering to International Quality Standards. The company irrespective of complexity, adhering to International Quality Standards. The company manufactures pistons for Automotive, Stationary Engines, and Compressors etc. The company manufactures pistons for Automotive, Stationary Engines, and Compressors etc. The company has competency in manufacturing pitons having Steel Struts, Alfin Ring Carrier and Oil Cavity has competency in manufacturing pitons having Steel Struts, Alfin Ring Carrier and Oil Cavity etc.

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Aluminum Piston Manufacturing Process

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Shorhort Nt Noteotes os on n MMakiaking Prng Proceocessss

The Rod

The piston begins as a three meter, solid aluminum rod. The reason aluminum is used is that it's The piston begins as a three meter, solid aluminum rod. The reason aluminum is used is that it's lightweight, rust-proof, and easy to cut. A saw th

lightweight, rust-proof, and easy to cut. A saw th en cuts the rod into smaller pieces called sluen cuts the rod into smaller pieces called slugsgs

.

The Punch

A punch press and dye are pre-heated while the slug moves through an oven, heating it to the A punch press and dye are pre-heated while the slug moves through an oven, heating it to the same temperature as the punch press. The slug is then removed from the oven, and placed into same temperature as the punch press. The slug is then removed from the oven, and placed into the punch. The press applies 2,000 tons of pressure onto the slug, forging it into the basic shape the punch. The press applies 2,000 tons of pressure onto the slug, forging it into the basic shape of a piston. This process causes the piston to become so hot, that it needs an hour to

of a piston. This process causes the piston to become so hot, that it needs an hour to

The Oven

After the forgings cool down, they go through an oven twice more. The first time is at a higher After the forgings cool down, they go through an oven twice more. The first time is at a higher temperature, to strengthen the metal. The second

temperature, to strengthen the metal. The second time is at a lower temperature to stabilize it.time is at a lower temperature to stabilize it.

The Lathe

A lathe is then used to cut excess metal from the basic form of the piston, taking it closer to its A lathe is then used to cut excess metal from the basic form of the piston, taking it closer to its finished shape. Then tiny holes are drilled in the sides, allowing oil to lubricate the piston when finished shape. Then tiny holes are drilled in the sides, allowing oil to lubricate the piston when it's in use. The same lathe then impresses three rings into the top of the piston. These rings, or it's in use. The same lathe then impresses three rings into the top of the piston. These rings, or grooves, help the piston glide, and

grooves, help the piston glide, and allow it to form an air-tight seal.allow it to form an air-tight seal.

The Wrist Pin Holes

A large hole is then drilled through both sides of the piston. This is where the wrist pin will go, A large hole is then drilled through both sides of the piston. This is where the wrist pin will go, attaching the piston to the connecting rod.

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The Milling Machine

A milling machine then shaves up to a couple of centimeters off of each side of the piston where A milling machine then shaves up to a couple of centimeters off of each side of the piston where the large holes were drilled for the wrist pin insertion. This is to reduce the overall weight of the the large holes were drilled for the wrist pin insertion. This is to reduce the overall weight of the piston.

piston. Another Another milling milling machine machine takes takes some some more more metal metal off off of of the the area area where where the the three three ringsrings were formed earlier, bringing the piston one

were formed earlier, bringing the piston one step closer to its final form.step closer to its final form.

Finishing the Job

Another lathe shaves a few more millimeters off of the top, allowing the piston to expand when Another lathe shaves a few more millimeters off of the top, allowing the piston to expand when heat builds up inside of it. Then a machine engraves model and production information. A heat builds up inside of it. Then a machine engraves model and production information. A human worker then smoothes out the sharp edges of the piston created during production. The human worker then smoothes out the sharp edges of the piston created during production. The holes created for the wrist pin are then put through a machine which smoothes them, allowing holes created for the wrist pin are then put through a machine which smoothes them, allowing the wrist pin to fit comfortably. Finally, the pistons sprayed by hot, deionizer water, removing the wrist pin to fit comfortably. Finally, the pistons sprayed by hot, deionizer water, removing any lubricant or oil gathered through the manufacturing process.

any lubricant or oil gathered through the manufacturing process.

The Process Which Is Performed In Work Shop to Making Piston

Incomming Raw Material

Aluminum Alloy in its various grades is procured from the secondary smelters, who alloy the Aluminum Alloy in its various grades is procured from the secondary smelters, who alloy the primary aluminum ingots to specifications as per national and international standards

primary aluminum ingots to specifications as per national and international standards..

The vendors for aluminum alloy are selected on the basis of Quality and timely deliveries. The The vendors for aluminum alloy are selected on the basis of Quality and timely deliveries. The vendors are periodically evaluated for Quality, Consistency an

vendors are periodically evaluated for Quality, Consistency an d On time deliveries.d On time deliveries.

Raw Material Grade

All incoming raw-materials (Aluminum Alloys) are subject to Optical Emission Spectrometer All incoming raw-materials (Aluminum Alloys) are subject to Optical Emission Spectrometer Analysis to determine metallurgical contents of various alloying elements. Strict compliance to Analysis to determine metallurgical contents of various alloying elements. Strict compliance to

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Piston Foundry

Casting aluminum for today’s Hi

Casting aluminum for today’s Hi-Performance pistons is a demanding science. All castings are-Performance pistons is a demanding science. All castings are cast on Semi Automatic & Fully Automated die casting machine in multipart permanent steel cast on Semi Automatic & Fully Automated die casting machine in multipart permanent steel molds. Melts are subject to modification, nucleation, degassing, etc. using FOSECO fluxes. Melt molds. Melts are subject to modification, nucleation, degassing, etc. using FOSECO fluxes. Melt preparation

preparation varies varies from from different different alloys. alloys. Dies-Mold Dies-Mold and and molten molten aluminum aluminum poring poring temperaturestemperatures are strictly monitored to achieve consistent casting quality.Dies and castings are periodically are strictly monitored to achieve consistent casting quality.Dies and castings are periodically subject to detailed inspection and decision to replace existing die taken.

subject to detailed inspection and decision to replace existing die taken.

Heat Treatment

All pistons castings are subject to Solution Treatment and Precipitation. Forced Air Circulation All pistons castings are subject to Solution Treatment and Precipitation. Forced Air Circulation furnaces with sophisticated programmable temperature controllers are employed for Heat furnaces with sophisticated programmable temperature controllers are employed for Heat treatment. Heat Treatment chart recorders establish traceability of every batch. treatment. Heat Treatment chart recorders establish traceability of every batch. The solution and precipitation cycle varies for different components on the basis of alloy used, The solution and precipitation cycle varies for different components on the basis of alloy used, section thickness of the components, physical requirements etc

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Inspection of

Inspection of Physical Properties

Physical Properties

All heat-treated casting batches ate inspected for hardness requirements. Castings not complying All heat-treated casting batches ate inspected for hardness requirements. Castings not complying with the specified hardness requirements are sent for heat treatment again.

with the specified hardness requirements are sent for heat treatment again. Periodically as perPeriodically as per inspection plan the castings are inspected for ph

inspection plan the castings are inspected for ph ysical properties i.e. tensile and elongation.ysical properties i.e. tensile and elongation.

Machine Shop

All pistons manufactured are machined on dedicated CNC & special Purpose Machines, which All pistons manufactured are machined on dedicated CNC & special Purpose Machines, which delivery high accuracy, consistency and repeatability. Close tolerances are maintained delivery high accuracy, consistency and repeatability. Close tolerances are maintained throughout via automatic machining and Statistical Process Control. Full automation is instituted throughout via automatic machining and Statistical Process Control. Full automation is instituted wherever it is consistent with improvements in cost and quality. wherever it is consistent with improvements in cost and quality. Pistons are subject to In-Process inspection as per Quality plan and Necessary corrective and Pistons are subject to In-Process inspection as per Quality plan and Necessary corrective and preventive

preventive actions takactions taken en on on the the basis obasis of the f the findings. The findings. The company company maintains maintains following qfollowing qualityuality records:

records:

SPC Chart SPC Chart

In-Process Inspection Format In-Process Inspection Format Operation sheet Format

Operation sheet Format Control Plan Format Control Plan Format Piston Drawing Piston Drawing Die Core drawing Die Core drawing

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Inspection

The company has Standard room equipped with measuring equipments to measure almost all The company has Standard room equipped with measuring equipments to measure almost all parameters

parameters of of pistons pistons with with greater greater degree degree of of accuracy. accuracy. All All pistons pistons are are subject subject to to 100% 100% visualvisual inspection and dimensional inspection of critical parameters. The Company employs the use of inspection and dimensional inspection of critical parameters. The Company employs the use of Air Electronic Gauging and Electronic Comparators with read-out systems capable of measuring Air Electronic Gauging and Electronic Comparators with read-out systems capable of measuring to an accuracy of 0.0002mm. (Least Count). All the measuring and test equipments are sent for to an accuracy of 0.0002mm. (Least Count). All the measuring and test equipments are sent for Calibration to NABL Accredited Laboratory as per the

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Surface Coatings

Surface coatings are a special process. These processes are established through process Surface coatings are a special process. These processes are established through process validation. Special process parameters are strictly adhered. Surface coatings include.

validation. Special process parameters are strictly adhered. Surface coatings include. Tin Plating Tin Plating Graphite Coating Graphite Coating Hard Anodizing Hard Anodizing

Inspection and Grading

The pistons are subject to visual inspection and grading as per customers requirements. The The pistons are subject to visual inspection and grading as per customers requirements. The pistons

pistons are are graded graded for for size size and and weight weight as as specified specified by by the the customer. customer. The The pistons pistons are are colourscolours coded or sizes engraved on the pistons crown for clear identification at the time of assembly at coded or sizes engraved on the pistons crown for clear identification at the time of assembly at

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Cost of making a Piston

Conclusion

All of ACL's performance orientated Race Series V8 pistons include some tricky design All of ACL's performance orientated Race Series V8 pistons include some tricky design